FJ60 4 speed transmission and TC in an FJ40

[nremorse9350]

Guys

I have a 11/73 FJ40 currently with factory 3-speed transmission and transfer case, with an 82 FJ60 2F engine.

My first question is. Will an 86 FJ60 H42 long transmission and split transfer case install in my 40.

Second question is. What will I need to complete this installation. I noticed the FJ60 has a crossmember brace for the transmission. will I need to incorporate this into my installation?

 

[brew8]

1. Yes it will but you will need to move the tubular crossmember behind the transfer case to fit the length. You will need to modify the driveshafts and the tranny hump to accomidate the shifter locations. You will also loose the emergency brake.

2. You can get by with them where they are. But lots of load out back, you may want to keep the crossmember fron the 60 and fab it in,

I did this conversion I liked the result. I used a conversion kit for the emergency brake it was pricy, not sure if they are available now.

 

[nremorse9350]

Thanks for the reply I will look into it. Do you have any pictures of your install that I can look at?

I'm wondering if it would be easier just to remove the transfer case from the four-speed and get an adapter gear to use my three speed transfer case with the new four-speed transmission.

 

[brew8]

I'll see if I have some, it was two cruisers ago, I'll get back today,

 

[Downey]

I'm not sure the 19 spline gear is available to let you use the FJ60 4 speed with your 3 speed transfer-case.

 

[brew8]

I don't think you can either, if thats what you want to do just get a earlier 4 speed and the conversion gear and spacers and your good to go, this combo is nice, quiet gears and smooth shifting, just not as easy as you might think, still looking for pictures.

 

[nremorse9350]

I don't think you can either, if thats what you want to do just get a earlier 4 speed and the conversion gear and spacers and your good to go, this combo is nice, quiet gears and smooth shifting, just not as easy as you might think, still looking for pictures.

So it sounds like I should just stick to the original plan of replacing both the three speed transmission and the three speed transfer case, do a little modification and be happy with the result.

 

[brew8]

Thats what I would do, you might search and see what others have done for the park brake.

 

[nremorse9350]

Thats what I would do, you might search and see what others have done for the park brake.

I am leaning towards that. I have complete access to the 60 drivetrain engine and all. Thought about using the rear axels with the incorporated Meg black hardware. Also I can remove the 60's crossmember and fab it in. I just wish someone might have some pics of this install to get my bearings straight.

1. Yes it will but you will need to move the tubular crossmember behind the transfer case to fit the length. You will need to modify the driveshafts and the tranny hump to accomidate the shifter locations. You will also loose the emergency brake.

2. You can get by with them where they are. But lots of load out back, you may want to keep the crossmember fron the 60 and fab it in,

I did this conversion I liked the result. I used a conversion kit for the emergency brake it was pricy, not sure if they are available now.

Brew8 do you recall where you saw the Meg brake conversion kit?

Anyone need some FJ60 parts?

 

[roma042987]

if your going through all that trouble id source a 9/85+ fj60 trans and transfer. it will have an extension housing that way if you ever decide to go with a 5speed it will be a direct swap with no fab work.

 

[Flipper1938]

I plan on doing the same swap on my FJ40. FJ60 trans/transfer case/ axles (with a chevy V8 though)

I need to finish the truck in my avatar first. Then I will get to work on the cruiser.

Take good pics when you do it.

 

[nremorse9350]

I plan on doing the same swap on my FJ40. FJ60 trans/transfer case/ axles (with a chevy V8 though)

I need to finish the truck in my avatar first. Then I will get to work on the cruiser.

Take good pics when you do it.

Will do. I plan on removing to trans/tc and engine this weekend on the doner.

 

[Flipper1938]

Will do. I plan on removing to trans/tc and engine this weekend on the doner.

If you want help, I'm just up I-65 from you.

 

[GreenGoat]

Subscribed, this conversion might be in my future as well.

 

[Living in the Past]

Do some research but I believe the top cover from a FJ40 four speed with bolt on to FJ60 transmission keeping the shifter in the stock location. On a 73 you shouldn't have to move the torque tube behind the transfer case. The 73 were already setup for a four speed. Because the 60 series split transfer didn't have hand brake clearance shouldn't be a problem. While everybody says you need to build a mount for the transmission a pre 8/80 FJ40 four speed bell housing will bolt in. Both to the motor mounts and transmission. Doubt the split case weights that much more than the one piece case with a PTO attached. Toyota added a four speed in 1973 in some markets and don't remember ever reading of any failures related to the bell housing motor mounts. If you use a 4/85 and later four speed then everything changes because it's longer and if you do go H55F which is heavier might as well do all your mods like torque tube and transmission mount now.

 

[nremorse9350]

If you want help, I'm just up I-65 from you.

Thanks. Will let you know.

Do some research but I believe the top cover from a FJ40 four speed with bolt on to FJ60 transmission keeping the shifter in the stock location. On a 73 you shouldn't have to move the torque tube behind the transfer case. The 73 were already setup for a four speed. Because the 60 series split transfer didn't have hand brake clearance shouldn't be a problem. While everybody says you need to build a mount for the transmission a pre 8/80 FJ40 four speed bell housing will bolt in. Both to the motor mounts and transmission. Doubt the split case weights that much more than the one piece case with a PTO attached. Toyota added a four speed in 1973 in some markets and don't remember ever reading of any failures related to the bell housing motor mounts. If you use a 4/85 and later four speed then everything changes because it's longer and if you do go H55F which is heavier might as well do all your mods like torque tube and transmission mount now.

thanks for the info. I will defiantly look into locating a 4 speed top cover. It was good to hear that I may not have to relocate the "torque tube". I will get some measurements on the transmission and transfer case this weekend (from the 4-speed bell housing back to the end of the TC and see how much clearance i have. I have also considered in using the FJ60's rear axel to re-use the built in emergency brake hardware (along with the disc brakes) of course that is more re welding of perches and some other mods. I might just stick to the original plan and first get the 4 speed installed and then tackle the emergency brake issue (any thoughts guys)?

back on the bellhousing, I still have the stock 4-speed hardware bell housing, clutch fork, fly wheel and inspection covers from my 82 2F engine as spares along with the ones from my FJ60. So if someone is looking these will be up for grabs soon.

Any way I will post up some pics of the situation both on my 40 and the 60 as it sits.

 

[nremorse9350]

Ok guys an update. First off I was wrong on the FJ60 date. The H42 long and split transfer case are from a 86 FJ60. Does this changes things?

After review of many things, I have concluded I will need to locate a pre 85 FJ60 crossmember and L brackets to support both the trans and TC and the rear portion of the 2F engine. Doe anyone know where I can source these?
I am aware that I will probably have to add spacers due to different frame widths with the 40 ad the 60.

86 FJ60 4-speed trans & STC

• nremorse9350
• Dec 13, 2014

It appears my 4-speed bellhousing does NOT have mounts for support as previously thought.

One more thing looking for the best examples of what other people have done to use either drive shafts from a 40 or from the 60. Obvious the 60 drive shafts will have to be shortened but not sure about the Split Transfer case out put flanges to the existing axels?

 

[nremorse9350]

Found a small clearance issue with the 2F bell housing. A little grinding and it should fit like a glove. "Got this from Poser. Thanks. Your write ups are amazingly helpful.

 

[nremorse9350]

A few more details on the process.

Going to have to relocate the slave assembly to the passenger side.

 

[nremorse9350]

Got the 3 speed and transfer case out.

Comparing the two side-by-side.